Apparatus and method for producing disk phonograph records



Oct. 14, 1952 A. l. MASSLER 2,613,395

APPARATUS AND METHOD FOR PRODUCING DISK PHONOGRAPH RECORDS Filed Feb 24,1949 12 Sheets-Sheet 1 c olvrkdl.

6O GAL- Oll. TANK ATTORNEY Oct. 14, 1952 A. l. MASSLER 2,613,395

I APPARATUS AND METHOD FOR PRODUCING DISK PHONOGRAPH RECORDS Filed Feb.24, 1949 12 Sheets-Sheet 2 Q \3 N ENTO TORNE Oct. 14, 1952 A. I. MASSLERAPPARATUS AND METHOD FOR PRODUCING DISK PHONOGRAPH RECORDS Filed Feb.24, 1949 12 Sheets-Sheet 5 Oct. 14, 1952 A. l. MASSLER 2,613,395

APPARATUS AND METHOD FOR PRODUCING DISK PHONOGRAPH RECORDS Filed Feb.24, 1949 12 Sheets-Sheg'i 4 TTORNEY Oct. 14, 1952 A. 1. MASSLER2,613,395

APPARATUS AND METHOD FOR PRODUCING DISK PHONOGRAPH RECORDS Filed Feb.24, 1949 12 Sheets-Sheet 5 E 15.7 I 1617 ll 157 i i 1626 168 m 157 & E168 i 165 E E INVENTOR a .z. M45515? Oct. 14, 1952 A. l. MASSLER42,613,395

APPARATUS AND METHOD FOR PRODUCING DISK PHONOGRAPH RECORDS Filed Feb.24, 1949 12 Sheets-Sheet a P4? m 5 Z25 :i I Z27 227 -3; 35 226 i g 5' zz I '1 ii. 160 210 f 160 I A210 250 I] I I I I l i Q n 229 ATTORNEY Oct.14, 1952 A. 1. MASSLER 2,613,395

APPARATUS AND METHOD FOR PRODUCING DISK PHONOGRAPH RECORDS Filed Feb.24, 1949 12 Sheets-Sheet 7 II I I II I III II I I I I III I I II IIIIIIIIII III II I I III IIII |l I II IIIII III I|I|||II|IIIIIIIIIIIIIIII INVENTOR A.I. MflSSLFAE g g, 2.73am

ATTORNEY Oct. 14, 1952 A. l. MASSLER 2,513,395

APPARATUS AND METHOD FOR PRODUCING DISK PHONOGRAPH RECORDS Filed Feb.24, 1949 12 sheets-sheeft 8 APPARATUS AND METHOD FOR PRODUCING DISKPHONOGRAPH RECORDS Filed Feb. 24, 1949 A. I. MASSLER Oct. 14, 1952 12Sheets-Sheet 9 INVENTOR Ar. flxzaz.

ATTORNEY i V 0 WI U! W V 4 A 9 6 M, 9 W 1 3% a 4 M E 4 mm Oct. 14, 1952A. l. MASSLER 2,513,395

APPARATUS AND METHOD FOR PRODUCING DISK PHONOGRAPH RECORDS Filed Feb.24, 1949 12 Sheets-Sheet 12 15 32 I M g Z 1 35 I 1 115 5/ #w 138 if 1 27,1; Ea 1w 1. .53 w E=-fmg 1r t Z 74 125 40 3 "1.211121221215711,

13 30 2/;- gut? 31 J5 Z1 46 44 a1 4 73 3? J1 a w 1 74 r 7 .1 W V 0 6'5 I438 WW ATTORNEY A. MASSLER Oct. 14, 1952 APPARATUS AND METHOD FORPRODUCING DISK PHONOGRAPH RECORDS Filed Feb. 24, 1949 12 Sheets-Sheet 11Q &

INVENTOR 6.1. P0955155.

/ATTORNEY as NWW Oct. 14, 1952 A. l. MASSLER 2,613,395

APPARATUS AND METHOD FOR PRODUCING DISK PHONOGRAPH RECORDS Filed Feb.24, 1949 12 Sheebs-Shet 12 T hNvJU U Qb 0 N k? 3A N EL . QQ MNNNQQPatented Oct. 14, 1952 UNITED STATES PATENT OFFICE APPARATUSAN METHODFOR PRODUCING DISKQPHONOGRAPH RECORDS Abraham I. Massler', Irvington, N.J assignor to M &-W Company, Inc., Newark, N. J., a cor-, poration ofNew Jersey ApplicationFcbruary 24, 1949, Serial No. 78.065

Claims.

This invention is directed tonovel inethods,

steps inthe methods, apparatus and sub-combi ratus in single or multiplerelationship may be" combined with a conveyor which receives andconveys'the records from the apparatus-and to deliver for labelingcompletely finished records ready for labeling.

The various advantages of the invention will be apparent from thefollowing description taken in conjunction with the drawings, wherein:

Fig. 1 is a View in side'elevation of'a machine embodying my inventionand alsoshows a novel combination of said machine anda conveyor forreceiving and conveyingthe'refrom records as they discharge from saidmachine.

Fig. 2 is a top plan view'of a disc phonograph record.

Fig. 3 is an enlarged and fragmentary crosssectional view taken on lineIII-411 of Fig. 2 in the direction of the arrows.

Figs. 4 and 5 are views mainly in cross section longitudinally with someparts shown in side elevation, and taken together at lines. A--Athereof, illustrating the operating mechanism of said embodiment of theinvention. 7

Fig. 6 is a fragmentary enlarged cross-sectional view taken on lineVI-VI of Fig. 4' in the direction of the arrows. I

Fig. '7 is an enlarged cross-sectionalview taken on line VII-VII of Fig..4 in the direction Ofthe arrows. I

Fig. 8 is a fragmentary enlarged crossesectional view taken on lineVIII-VIII of Fig. 4 in. the direction of the arrows. V H

Fig. 9 is a fragmentary enlarged cross-sectional view taken on lineIX-IX of Fig.4 in the direction of the arrows.

Fig. 10 is a fragmentary enlarged cross-sectional view taken on lineXXioi Fig. .4 in the direction of. the arrows. L a

Fig. 11 is'an enlargedcross-sectional view taken on line Xl-XI of-Fig. 4in'the direction of the arrows.

Fig. 12 is a fragmentary enlarged crosssectional view taken on line XII--XZI of Fig. 4 in the direction of the arrows.

Figure 13 is a fragmentary enlarged cross sectional' view taken on lineXIII-XIII of Fig. 5 in the direction of the arrows.

Fig. 14 is an enlarged cross-sectional view taken on line XIVXIV of Fig.5 in the direction of the arrows". V

Fig. 15' is an enlarged cross-sectional view taken on line XV-XV oiFig.5 in the direction:

of the arrows.

Fig. 16 is a cross-sectional-viewtaken on line XVIXVI- of Fig. 5in. thedirection of thearrows.

Fig. 17 isa fragmentary enlarged top plan view takenon line XVII-XVII ofFig. 5 in the direction of the arrows.

Fig. 18 is an enlarged longitudinal mainly cross-sectional viewwith someof the parts in side elevation of the central part ofthe mechanismshownin Figs;- 4 and 5 as combined, but with the dies closed.

Fig: 19 is a ioreshortened view similar to Fig. 18 and shows therelativeposition of parts at the end of the injection of the plasticmaterialinto the closeddies.

Fig. 20 is a View similar to Fig. 19 and shows the relativeposition ofparts when the sprue re-' moverhas accomplished its functions.

FigJZl is-a view similar to Fig; 20, and shows the die heads in openposition and before retraction ofthe'sprue remover has been initiated.

Fig. 22 is'a view similar to'Fig. 20; except that the stationary dieheadand parts thereabove havebeen omitted and showstherecord about toactuate a micro-switch in' the course of its in side elevation, and alsothe novel hydraulic circuits innovel combination therewith. v

Fig.'25"is a schematic View showingthe'various operations and thetimerelation of operations during a complete cycle of operation.

'Secured to the floor or any oth'ersu'itable support or base; is ahorizontallydisposed elongated sight 6 in one side thereof and a supplyinlet 1 at one end thereof (Fig. 1). The tank 5 is oblong in top planview and is of strong and rugged construction to support the variouselements hereinafter described, whereby the entire assembly may occupyonly a limited amount of space so that the assembly is compact, andtherefore, a plurality of them may be so arranged within a prescribedarea in such a manner that a single workman may take care of a gang ofassemblies, and a single conveyor may be utilized for receiving discrecords 8 having the usual opening 9 therethrough, as they are fedthereto from the various molding machines.

Supported by the tank 5 is a single, unitary casting I comprising a pairof supporting frame or tension members II, an abutment platen I2extending across the space between the tension members II, a clampingcylinder I3 and a supporting and connecting bracket I4 extending fromcylinder I3 and terminating in feet I5. The abutment platen I2 which isintegral with the tension members II is so disposed as to be at rightangles to said tension members II and has its center-line approximatelyparallel to the iongitudinal center lines of the tension members II andcoincidental with the longitudinal centerline of the cylinder I3. Thecasting I0 is mounted on the fluid tank 5, with the mounting feet I5lying on the horizontally disposed top of the tank 5 at one end thereofand firmly connected thereto by bolts or any other convenient means.

The plane of the bottom face of the feet I5 is at an angle of 35-55 andpreferably 45 to the longitudinal axis of the cylinder I3, so that thecasting I0, mounted as shown in Fig. 1, has its longitudinal center-linedisposed at 35-55 and preferably 45 to the horizontal, with each of thetension members I I being in a vertical plane, and

having its longitudinal axis at 35-55 and preferably 45 to thehorizontal, and with the abutment platen I2 disposed at an angle of35-55 and preferably 45 to the horizontal.

The clamping cylinder I3 has a pair of communicating and enlarged boresI6 and I1 (Fig. 4) A cylinder head I8 having a port I9 through thethickness thereof is secured to the lower end of the cylinder I3 bycapscrews 26 and carries a conventional sealing ring 2| to aid insealing the head I8 to the cylinder I3. Slideably mounted in theclamping cylinder I3 is a piston ram 22. The extreme lower end 23 of theram 22 is of reduced diameter to provide an annular space 24communicating with the port I9 and a port 25 through the side of thecylinder I3.

A portion of the ram 22 adjacent the end 23 is of increased diameter toprovide a piston head 26 approximating the diameter of bore I1 ofcylinder I3 and carries a plurality of conventional piston rings. Thecylinder I3 has a port 28 extending through the side thereof andcommunicating with the space between the upper part of the bore I1 andthe piston head 26. Bushings 29 and 30 with packing 3| locatedtherebetween are disposed in the space between the upper part of the ram22 and the bore I6 of the cylinder I3. The upper faces of the cylinderI3 and the bushing 30 are recessed to receive an annular retaining ring32 which is anchored to cylinder I3 by capscrews not shown. The ram 22has an elongated well 33 therein with the longitudinal axis of the wellbeing coincident with that of the ram 22 and the cylinder I3. Located insaid well and spaced from the sides thereof is a cylinder 34 whose upperend terminates in an outwardly extending annular flange 35 and isanchored to the eating with the bore 43.

piston ram 22 by means of cap screws (not shown) extending throughflange 35 and into ram 22, so that the cylinder 34 is driven by and maybe reciprocated in unison with the ram 22. The lower end of the cylinder34 is closed by a cylinder head 36 carrying a conventional sealing ring.A unitary assembly 31 includes a plurality of in-line piston heads 38,39'and 46 connected to each other. The piston head 33 is slideable inbore 40 of the cylinder 34 and carries conventional piston rings toprevent leakage. The outer end of the flange 35 has an annular recess 4|therein.

An inserted cylinder head 42 only partially depends into the bore 40 ofthe cylinder 34, has a bore 43 and has'an annular flange 44 extendingoutwardly therefrom and located in the recess 4|. A conventional sealingring is carried by the cylinder 34 and is located between the cylinder34 and the head 42 toprevent leakage. The piston head 39 is slideable inthe bore 43 and carries conventional piston rings to prevent leakage.Extendingthrough the flange 35 and the flange 44 are communicatingopenings which together provide a fluid passageway 45 communi The pistonhead 46 is also slideable in the bore 43 and carries a conventionalpiston ring to prevent leakage. Extending outwardly beyond the piston 46and integral therewith is a cylindrical record pusher or stripper 41whose axis of reciprocation is coincidental with that of the pistonassembly 31 and the longitudinal axis of the cylinder I3. The triplexpiston assembly together with the stripper 41 provide a single unitaryhollow element 31 open at both ends and having bores 50, 5|, 52

and 53 respectively, (Fig. 18) of gradually increasing diameters fromthe inner to the outer end thereof.

A compound piston assembly 55, consisting of in-line piston heads 56,51, 58 and 59 are connected to each other, and each carries one or moreconventional piston rings to prevent leakage. Integral with andextending outwardly from the piston 59 is a ram rod 60 which serves as acore and a record hole punch and sprue remover. Note Fig. 19 in whichthe rod 60 is shown in its coreforming position and Fig. 20, where therod 6Il'has advanced to push out part of the cast rod, the sprueportion, and moved it into the nozzle I I I. The sprue is formed withinthe die cavity and is removed after the product, or record, is formedand re-melted in the heated zone of the nozzle I I I.

The piston head 56 is slideable in bore 6I of cylinder 34, pistons 51,58 and 59 are respectively slideable in bores 50, 5| and 52, and rod 66is slideable in bore 530i stripper cylinder 41. The rod 60 is of adiameter corresponding to that of the opening 9 through the center ofthe common disc record 8 and its outer extremity is in the form of ashallow cone or teat 62, whose base has a diameter less than and usuallyabout .5-.75 that, the rod which together comprise the rod 60. Theunitary element or ram rod comprising the assembly and the sprue rod areso proportioned that when it is in lowermost or completely retractedposition as shown in Figs. 4 and 18, the upper end of the rod 60 at thebase of the cone 62 is disposed outside of the'outer face 63 of thestripper 41. The lower end of the piston 56 is recessed to provide aspace 64 communicating with a fluid passageway 65 in the cylinder 34 andthe flange 35 (Fig. 18). A transverse fluid port 66 extends through thepiston assembly 31 at a place between. the pistons 39 and as. The port06 communicates with the bore 51 and the bore 43 which in turncommunicates with the fluid passageway 45. A. transverse fluid port I5extends through piston assembly, and communicates with'bores 40 and 50.A fluid passageway 61 in thepistonram 22and the cylinder 34comr'nunic'ate'swith the space 24 and the upper end of boreflfli'i'nturn communicates with the upper end of bore 50 throughpassage 15. Afluid passageway 08 in the piston ram 22 and the cylinder 34communicateswith bore I7 above the piston 29 and on that side of thepiston head opposite from that at the lower e'n d'of passageway 61, andwith the bore 40 at the lower end thereof;'the bore 40 inturn-communicating with the upper end of bore 61 through passages l0.

The retracted stroke of. the reciprocable-ram rod is limited by thelower face of 'the'ram' rod abutting against a face of the cylinder head30; and the advance stroke of the ram rod is limited by the outer face09 of the piston head 56 abutting against the inner face of themulti-p'iston and stripperassembly 41., the inner end of which assemblyextends beyond the face. of the bore "61 and towards the center-linethereof, with said end havin the grooves or'passagewaysf'lll thereincommunicating with the bores 40 and '61.

A die head II has a central bore .theret'hrough, a recess in the bottomface thereof anda recess in the upper face thereof. The die 'head TI-ismounted, with the 'strip'perfd'l extending through the central bore ofthe die. head II and the flanges 35 and 44 located in theflofwer recessthereof. The die headll issecured'to the flange 35 by capscrews (notshown). Mounted in the recess in the upper face of the die head II is adie assembly or unit I2 comprisingademountable matrix support 13 havinga central bore through which passes the stripper '411, having a shoulderring BI and an inner 'annular' re'ce'ss the contour of whose upper orouter portion tapers inwardly downwardly towards the supportin face ofdie head H. A record matrix "I6 lies 'flatewi'se on the outer face ofthe 'matrixsuppOrt I3. An inner retaining ring I4, having a center boreaccommodating the stripper 4'1, islocatedin the inner recess inthematrix support I3.

The support I3 has a tapered'or conical upper end contiguous with thetapered end :of said retainer 74 extending outwardly beyond the matrixsupporting facefof the-support "I3 and slightly lappingo'ver'thebevelled inner'periphery edge of'the matrix I0 sq that when the capscrews 88 passing throughfthe retaining ring 82 andintothe die head II,are tightened, the. retamin ring 82 comes home iintheconical. peripheryof the recess indie head I I and simultaneously clamps together. thematrix I6 and the shoulder portion 9| of thering'82. The shoulderportion SI has a bevelled surface which forms a bevel on the peripheryof the moulded product 335, or the record 8. s

Thedie head II has a plurality of shallow cylindrical cavitiesspacedtherearound and located therein. Located ineach of the cavities isof th matrix T6 to serve as a temporary record retainer or holder. Theretaining ring. "I4 is locked in position, with the outer inwardlyinclined periphery thereof lapping over the inner bevelled periphery ofmatrix I6, bycapscrews passing through the matrix support 'I3Jandfintothe ring 14. The outer diameter of the'matrix i6 is equal to thecorresponding dimension of the matrix supporting face of "support "I3.An outer retaining ring 82 has a counter recessed portion matching theshoulder firing '8I and-has an outer peripheralcontour'matching thetapered or conical bore surface of'the inner recess in the die head -II.narrow interior'shoulder or flange 90, the thick-, ness of which isequal to'one'half'the thickness of the disc record 8 to be made. Theinnermost portion of the flange 90' is bevelled or otherwise tapered toprovide a shallow taper conforming The retaining rin 82 hasja The innershoulder 9| laps over the outer-- a displacing spring 93; .(Fig 1 1)which is :normfally compressed -by thedie assembly 12 and serves to aidin breaking loose the-outerretainlng ring 82 when the screwcaps 88 areloosened in the course of disassembling the assembly I2 for changingmatrix '16. The die'head H has an inlet port' and an outlet port 96communicating with a water circulating passageway 9'! for the passage ofcooling water therethrqugh for reducing the magn'itude'of the curingperiod. A stationary die head 98 (Fig. 1 8) is secured by cap screws(not shown) to face of the abutment platen I2ha'vlng acentralopening'through the thickness thereof. The. head 98ispart of 'adie assemblage, or unit, substantially the same as unit I2. A pair ofaligningmaledowels I04 (Fig. 4) extend from die head 03 for mating withdowel bushings I05 (Fig. 11)fcarried by the die head 'II forassu'ringtrue alignment '01 "the dies. The die head 98 hasin'let and 'outletports liit at the ends of passageway lflijtherein for the p'assagetofcooling'water therethrough. The die head"98'h'as acentral openingaccommodating a spru'e'bushing '99 '(Fig. 18') fidentical'in transversecross section'with the stripper 4'1andhaving a concave spherical nozzleaccommodating 'recess or scat I09. A matrix I00'is coupled with thegdiehead 98 in precisely the same manner as the matrix I6 is coupled withthe movable diejhead II, except that the b'evelled'edge of the innerretaining ring 14 onthe head "II is'slightly-further beyond the inner'edgeoimatrix .I'B 'so-that itenters deeper into'th'e recordiii for thepurpose of causing the record to adhereto it after the dies'are partedand toberetainedthereto, The mold cavity is formed in each die'unit by"bore formingelements 41, 99; ring I4; matrix'lfi, I09 and ring 02, noteFig. 23 of the drawing.

'The spherical seat I09 is'complementaryto and mates withthe sphericalsurface H0 at the discharge end of a nozzle I I I or aninjectioncylinder or'chamber I20. Located between the tension members II is asaddle bracket 1H5 and a clamp cap .II6, connected "to. each other bymeans of capscrews I I1 (FigJIB). The injection cylinder I20, having anoutwardly extending shoulder or flange I2I at the. upper end thereoflissupported by the bracket H5 and clampedthereto by the thrust cap II6,'to'firmly anchor the cylinder I20 against lateral 'motion.

The "flange I2I '(Fig. 5)bears against one end of the clamp comprisingbracket I IB-cap I Hi and is tightened thereagainst by'means of a thrustnut I22 engaging a threaded portion. of the cylinder I20 to fix cylinderI2 0 against longitudinal movement relative to bracket H5. The clamp hasinlet and outlet openings communicating withpassageways'for'the'circulation of cooling watertherethrough for thepurpose ofmaintaining the fusible granular material at the. upper end ofcylinder I20 from'gummingup andimpeding feeding. The injection cylinderI20 is elongated and has an elongated opening I23 or bore extendingtherethrough and is so disposed that its longitudinal center line iscoincident with the longitudinal center line of bore through bushing 99and that of the cylinder I3. The lower or inner end of the cylinder Ihas a threaded portion on the inner face' thereof and also has a recessor counter bore on the inner face of a portion thereof adjacent thethreaded portion to provide an abutting shoulder (Fig. 18).

A spreader I is located in the lower end of cylinder I20 and'terminatesin a head I3Ineat fitting in the counterbore atfthe lower end ;of,cylinder I 20 and bearing against the abutting shoulder. The nozzle IIIhas an outwardly extending flangel25 contiguous with head I3 I. Thenozzle III extends'through a thrust nut I32.in threadedengagement withthe lower threaded end of cylinder I20 and when tightened against theflange I25, forces it against head I3I to form a seal between theabutting shoulder in cylinder I20 and head I3I. The nozzleIII, nut I32and the lower end of thecylinder I20 pass through a central opening I21,through the abutment platen I2 and into an opening I26 in die head 98and communicating with the bore of bushing 99..

The spreader I30. .hasa barrel I33 tapered as seen at I34 wherein itjoins a rod I35 which. ex}- tends into and makes a" neat sliding fit inthe bore I36 of aninjection plunger I31. I3I has a multiplicity of holesI38 with streamlined pockets for leadingmateri'al into the holes andtogether with compartment I39 form passageways for material to flowintothe nozzle I I I through its opening I40 communicating with and taperedreductively downwardly to an orifice MI and then tapered increasinglydownwardly to the discharge terminus thereof, which terminus is acylinder of 'the'same diameter as the opening through sprue bushing, 98and in alignment therewith.

The cylinder I20 may have a plurality of elec. tric heating bands Iclamped therearound. These heating elements may be of the necessarywattage to properly soften plasticize,'or reduce the viscosity of thematerial'to be injected at the rate desired. The energization anddeenergization of these units maybe remotely controlled by any suitableinstrument to control the temperature of said material as desired, andgenerally through a thermostat I5I located at the lower end of thecylinder I20 and near the nozzle III.

A hopper I containsa supply of granular or comminuted material I58,which is essentially fusible and thermoplastic, such as the vinyl orother resins and employed for the molding of disc phonographrecords(Fig. 5). Thehopper I55 has a discharge outlet rigidly secured to theclamp H6 by bolts I51. The clamp cap H6 together with bracket II5 aswell as the cylinder I20 have aligned openings also aligned with hopperoutlet to provide a pasageway I56 from the hopper I55 to the bore ofheating cylinder I20. The passageway I56 is disposed substantiallyVertically so that the plastic material may automatically, and actedupon solely by the force due to gravity, feed directly into the bore ofcylinder I20 through passageway I56. Each of the tension members II hasan elongated slot I (Fig. .1) along the longitudinal center linethereof. The slots I65 are so arrangedthat the slot. in one member II isopposite thev corresponding slot in the other member.

Each-side r e r the diehead 1| '(Figfll) has The head a an elongatedtapered guide groove I66 along its longitudinal center line. Adjustablebearing shoes I61 have bearing. faces complementary to the tapered facesof the bearing grooves I66 and disposed therein. These shoes I61 passthrough the slots I65 and terminate in outwardly extending flangesthrough which extend a plurality of capscrews I68, and also a pluralityof set screws I69. These various screws I60 and I69 mayibe adjusted foraligning the die-head and also provide the desired sliding bearingbetween the shoes I61 and guide grooves I66.

Located in the space between a pair of side plates 2I0 (Fig. 13) are apair of tension members I60 disposed substantially parallel to saidplates. Each member I60 has one end thereof integral with thesupportingbracket H5 and its other end integral with a cylinder I6I whose centerlinecoincides with the center line of cylinder I3. The two members I60,saddle bracket H5 and cylinder I6I.may together be a unitary, singlecasting. The cylinder I6I has bores I10 and I12 therein (Fig. 5). Agland flange I1I is secured to the lower end of the cylinder I6I bycapscrews I15, and carries on its bearing face a conventional sealingring to prevent leakage.

A cylinder bushing I13 makes a tight fit in the lower bore I10. Withinthe gland flange I1I is a gland bushing I16, and between the glandbushing I16 and the cylinder bushing I13 is a set of cheveron packingI18. The gland flange I1I has a transverse port I18 communicating withthe internal bore thereof to act as an oil leakage outlet; and thistogether with the sealing ring in the gland flange I1l prevent any oilwhich may leak past the bushing I16 from reaching th injection plunger I31, which is kept dry at all times. A piston ram I is located in thecylinder I6I and includes a piston head I82 having a plurality ofconventional piston rings for preventing leakage. The piston head I82 iscentered by and makes a free sliding fit in bore I12. The remainder ofthe ram I80 is also centered by and makes a free sliding flt in thebores of the cylinder bushing I 13, gland bushing I16 and the glandflange I1I. The lower end of the ram I80 has a counter bore recesstherein, in which is located a plunger head I85, in the nature of aflange and integral with the cylindrical plunger I31 at one end thereof.A plunger retaining ring I81 bearing against the shoulder of the headI85 is secured to the ram I80 by capscrews I 88. The ring I81 maintainsthe head I85 of the injection plunger nestled in the recess at the endof ram I80, so that it is free floating diametrically but is closelyconfined laterally with very little, if any, thrust freedom.

The cylinder I6I ha a transverse port I89 therein communicating with thebore I12 at the lower end thereof; the cylinder I6I also has anothertransverse port I90 therein and communicating with the bore I12 at theupper end thereof. The upper end of the ram I80 has a centrally disposedwell I90 therein. A cylinder head I is centered with and attached to thecyldiner I6I by capscrews I96. This cylinder head I95 carries aconventional sealing ring to prevent leakage between the cylinder I6Iand the head I95. The cylinder head I95 has an elongated compartmentI91, the closed end of which extends downwarly into the well I90. Thecompartment has a lower bore I98 and an upper bore I99. The bore I99 isfitted with a cylinder bush- 59 or compartment I01 has a piston rod 204extending through the open end thereof and making a bearing fit with thebushings 200, 20I and packing 203. The lower end of the pistonrod 204carries a piston head 206 carrying a plurality of conventional pistonrings and located in bore I 98, which is of greater diameter than thebore of the bushing 200. A gland flange 208 is secured to the outer endof the compartment of cylinder I91 with capscrews 200. In this mannerthe cylinder head I95 is secured in fixed relationship with respect tothe cylinder I6I and'may be employed to impart motion to the cylinder I6I, and the injection cylinder I20. The -head I95 has a transverseopening I9I terminatingjust'below the bushing 200 to thereat.

A frame (Fig. 1) comprises a pair of side plates 2H0. having recesses inthe inner sides of the upper ends thereof, and an abutment cross member2I3 whose "ends are located in said recesses and is secured to said sideplates by capscrews 2I4. These side'plates 2I0 are spaced from eachother, are disposed substantially as a continuation of the tensionmember I I, and each has its longitudinal center line coincidental withthat of the corresponding tension member II. The lower ends of said sideplates 2I0 are accurately located and secured to the abutment platen I2by cap'screwsj2l' 5vand dowels (not shown). The abutment cross member2I3 has a central opening therethrough, through'which extends a reducedthreaded end ZI'I (Fig. 5) of the piston rod z'nramiis cdupledtherewithin abutting relati'onshi'pby a' nut 2 I8 on the threaded end 2Il. Anelongated port 22I extends through the piston rod 204 an piston head 20Band communicates with'the bore I98. The side plates 2I0 (Fig. 1) have'aplurality of elongated slots 225 similar to'theslots I55 and inlongitudinal alignmentv withis aidmslots, with'each slot 225 in one sidebeing; directly oppositea correspondingslot in the other side 2I0. Theten.- sion members I50 (Figs.p l3 and 14) have longitudinally extending.bearing grooves therein in alignment with and ."similar to the bearinggrooves I66 of head II. A bearing shoe .221 which extends through eachof the slots 225, has the bearing 'end'threof against the bearing facesof the groovef22j6 and has a plurality of screws 220and 290I'simila r tothe screws I68 and I69, and serving the purpose as said screws I68 andI69.

A plurality of brac'es230farld 23I (Fig. 14) extend across thespacefbetween the side plates H and are secured thereto by capscrews232, and act as brace separators. The brace 23I (Fig. 5) has a bushingtherethrough accommodating a, shaft 233extendingtherethrough and havingone end thereof lkey'ed to a handle or release lever 234', The nther.endof the shaft has a spur gear 235(Figs. l6 and 17) keyed thereto. Apairof idler spur gears 236 and 231 mesh with the spur gear235 and aremounted on top of the plate 2I3. (Fig. 17). Also mounted on the top ofthe plate 2I3 are spur gears 238 and 239 respectively meshing with theidlers 236 and 231. The spur gears 238 and 239 are respectively keyed tothe shafts 240 and MI. Keyed to said shafts 240 and MI (Fig. 16) anddisposed below the plate 213 are a pairofeccentric cams 242 and 243,which in certain normal operating positions act as spacers between theabutment plate 2I3 and the flange 208 for limiting the stroke of theinjection unit to a communicate with the bore I98 small'incrementofapproximately one thirtysecond of an inch when fluid pressure isapplied through the port I9I and port 22I is connected with exhaust. Therelease lever 234 may be moved to rotate the shaft over an arc of (Fig.17) and acts through the train of gears to rotate the cams 242 and 243to either operative or inoperative position. The lever carries a springactuated ball detent 245 so when the lever is in one extreme positionthe ball 246 drops in a hole in brace 23I for latching as shown in Fig.5. I

When the releaselever 234 is placed in the other extreme position theeffective parts of the cams 242 and 243 are turned outwardly and aredisposed in the dotted line or inoperative position shown in Fig. 16.When so disposed the cams permit the gland flange 208 to pass betweenthem allowing the longer stroke to occur whenever pressure is admittedto passageway IBI and passageway 22I is connected to exhaust.- V

A vertically disposed supporting column or housing 250 has feet 25Iresting upon the top of the tank 5 near the side thereof away fromthecylinder I3. The column 250 is rigidly secured to the tank throughsaid feet 25I by bolts 252. The upper end of the column 250 is securedin any convenient manner to the-upper end of the side plates 2I0 as wellas to the end plate 2I3. The column 250 houses the various controls, anddials at desirable operating levels. It also houses the valves, piping,timers, etc., while bridging a coupling which connects an electric motor260 to a pump 26I, both of which are secured to and supported by the topof the tank 5 and are disposed on either side of the column 250. Thepower unit consists of an electrically driven rotary piston variabledisplacement pump with built in gear pump for larger volume (lowpressure) and an internal gear pump for pilot operation of variabledisplacement pump and operation of hydraulic directional valves. Thepilot operated valves are electrically controlled to attain automaticoperation through action of buttons, limit switch and electric timers.

Ventilated removable guards 263 are provided to completely house thepower unit, which initself is conventional. An endless belt conveyor 330extends transversely of the machine and has a receiving stretch thereoflocated in the space just directly below the movable die head II when inopen position to receive a disc 8 record as it is stripped from thematrix I6 by the stripper 41 and then acted upon solely by the force dueto gravity, moves downwardly to. trip the microswitch and thence tochute 33!. The chute 33I serves to guide the record and turn it toflatwise position, in which position it is deposited on the conveyorbelt 330. 1

As shown diagrammatically in Fig. 24, there is a supply line 400connecting the supply tank 5 to the high pressure pump of the compoundpump 26I, which high pressure pump supplies the oil through a highpressure supply line 40I connected thereto and to a conventionalfour-way solenoid operated valve 402 having two solenoids 440 and MI andhaving a return line 424 to tank 5. The stem of a high pressure branchline 403 is connected to valve 402. A branch of line 403 is connected toport IOI and its other branch is connected to port 28 The stem ofanother high pressure branch line 404 is connected to valve 402. Abranch of line 404 is connected to port 25 and its other branch isconnected to port 22l. A check valve 405 is in the stem'of the branchline 404, just prior to the juncture between the stem and branchesthereof.

An adjustable relief valve 408 is connected to the stem of the highpressure line 404 at a place between valve 402 and check valve 405 andto the branch thereof connected to the port 25. A normally closedthree-way'valve 401 having a solenoid 442 is operatively connected tothe relief valve 406 and has its inlet side connected to' the stem ofthe line 404 by pipe 408 at a place between the valve 402 and valve 405.A pipe 409 connects the outlet side of valve 401 to the tank 5. A lowpressure line 4 having a check valve 4| therein is connected to the lowpressure pump of the compound pump 28| and to the port IS. A normallyclosed'two-way hydraulic operated spring return valve M2 is connected tothat branch of the high pressure line 403 which goes to the port 28 andis also connected to the low pressure line 4 0, at a place between theport I9 and the check valve 4| and has a tank return pipe. The highpressure line 40| isconnected to a sequence relief valve M5 by line M6.The sequence relief valve 4|5 in turn is connected by line M1 toasolenoid controlled hydraulically operated four-way valve 4|8havingsolenoids 443 and 444 and having an exhaust line 440 returning totank 5. A line 4|0 branches off the line 404 and is connected to a dialpressure gage 420 through a gage stop valve 42L A high pressure line 425extends from the high pressure pump of the compound pump26l to the valveM8 and also to the line M1 and to a dial gage 426 by way of a stop valve421 through a line 428 connected thereto and also to the line 4|1. Asolenoid operated spring return threeway pilot valve for duplexoperation 430 having a solenoid 445 is connected 'tothe pilot pressureline 43L Valve 430 is connected to the' control on low pressure pump ofthe compound pump 26| and has an exhaust connection to tank 5. Line 43|connects the internal gear pump (commonly called pilot pump) to the twopilot valves of the four-way valve 418. A high pressure line 435connects the valve 4|8 with the port I90 and a high pressure line 438,having an oil gear foot valve 431 therein is connected to the valve M8and the port I89. sageway 65 and to the line 436 at a place betweenvalves M8 and 431. A line connects line 40| to control for low pressurepump.

The pilot pump delivers only a small quantity of oil, about six gallonsper minute at about 150 pounds per square inch. Within the pump thisacts to keep the high pressure pump at full volume. The line 425 isleading the system pressure back to the pump to so act that when thesystem pressure reaches the pressure as set at the pressure adjustmenton pump, this pressure acts to overcome the pilot pressure and volumedelivered by the high pressure pump is reduced accordingly. When thesystem pressure is reduced by shifting of a valve or otherwise, pilotpressure acts again to push the pump to full volume. When pilot pressureis admitted from line 43| through valve 430 to act in one direction onthe control of the low pressure pump, the delivery of the pump goes toline 4|0. Then when the control is exhausted through valve 430 to tank 5the flow is diverted to cooler. The opposite end of control is connectedthrough the branch to high pressure line 40| so that'when systempressure builds up to equal the low pressure set- Aline 438 is connectedto pasting at'th'e pump the pressure is admitted to shift the control soas to divert the flow to the cooler. Even when solenoid 445 isenergized, the pilot pressureis acting on the control, the systempressure will boss and the low pressure pump will be unloaded to thecooler while the system pressure continues to build up to high pressuresettings.

All of these lines, the valves, as well as the timing-circuits andmechanisms, not shown, are all conventional and per se are not myinvention, and may all be disposed above the top of the tank'5 and arelocated within the side limits of the tank and tension members plates 2l0 and the vertical housing 250 to provide an elongated, relativelynarrow, compact independent single unit, occupying only a limited amountof space and with a conveyor belt 330 extending transversely-through thespace between the angularly disposed operating mechanism and the tank,so as to receive records from the machine.

Operation With the parts disposed in their relative positionsas shown inFigs. 4 and 5, the die is completely open and the movable die head 1| islocated in its maximum retracted position lim ited by the lower face ofthe piston ram 22 butting against a face of the cylinder head l8. A stepby step complete cycle of operation is as follows: By manipulating thevarious controls carried by the column 250, the motor 260 together withpumps 26| are placed in operation and so maintained during the operationof the machine for providing the desired fluid pressure in the varioussupply lines, which is visibly indicated to the operator by dials 420and 426 on the board 250. At this stage B, before the automatic cycle isstarted, all the solenoids are in the deenergized state, with the duplexpump volume being circulated through the cooler and the high pressurepump volume being circulated back to thetank 5 through valve 402 and thevolume from the low pressure pump is flowing to the cooler. At the stageB shown in Figure 25 all of the solenoids are in the de-energized stateand upon actuation by the operator of the starting button 500 theautomatic cycle is started. The solenoids I and 445 become energized tocondition the valves 402 and 430. The adjusted valves 402 and 430connect the port 28 to exhaust through the line 403 and at the same timehigh pressure pump volume passes from the valve 402 through relief valve406, line 404, port 25 through the lower part of the clamping cylinder3.

While'the oil is thus admitted under pressure into the space 24 of thecylinder |3 from the line 404, oil is also admitted thereto from the lowpressure pump through the line M0 and port l9. Pressure is exerted onthe lower face of the piston head 26 of the ram 22 by the oil from boththe lines M0 and 404, and particularly by that from the line 4|0 due tothe large volume of oil conveyed thereby. This causes the clamping ram22 together with the parts operatively connected thereto to move up ata. fast speed on a centerline coincidental with that of the cylinder l3.At the same time the oil is admitted into the lower part of the cylinderl3, it in part passes through the passageway 61 and into the upper endof the bore 40, and acts upon the piston head 31 to move the stripper 41from dotted li p s tion shown in Fig. 22 to and 13 maintain it in fulllinelposition shown in Fig. 24, because the bore 40 onthe other side ofpiston 31 is on exhaust through the passageway 68, bore I l and line 403through thevalve 402 and line 424 to the tank 5, andalsofrom bore 40into the bore 50 toact upon piston 51 to keep the ram rod in retractedposition. The clamping ram 22, now traveling at a relativelyhigh speed,actuates limit switch 450 at stage K whereupon timer Ta is started,solenoid 445 is de-energized, thereby conditioning valve 430 so thatduplex pump volume is by-passed through a bypass valve in this pumpthrough the cooler'to the tank 5, while the high pressure volumecontinues to move ram 22 forward and solenoid 443 is energized toactuate the control valve 4I8, thereby connecting line 435 to line 4Hand placing line 436 on exhaust through valve 418. As the oil is beingunloaded to the cooler, the slight remaining gap between thedie heads isclosed by the slow travel of the movable die head I! eifected by onlythe, additional volume of oil supplied to the cylinder I3 through theline 404 resulting ina slow speed kissing of the dies. The oil from thehigh pressure line 404 continues to feed into the clamping cylinder [3and at stage C builds up an initial clamping pressure between the diesof about 1500 to 2000 pounds per square inch and is automaticallycontrolled and maintained by the adjustment of the relief valve 406. Atstage C and simultaneously with the building up of said pressure betweenthe dies, oil is admitted through the other branchof the high pressureline 404 through the opening 22! into the bore I98 and acting againstthe top end thereof, forces the cylinder it! together with the injectioncylinder I20 and nozzle head II! to travel downwardly a slightdistanceof the order of one thirty-second of an inch along a centerlinecoincidental with that of the cylinder I3 to firmly seat the sphericalend of the nozzle head ill in the concave seat I of the sprue bush ing99 later to prevent leakage of plastic material at this juncture. Thisis completely effected at stage D and is quickly accomplished in theinitial part of the period between stages '0 and G, in which period thedies are constantly maintained under initial clamping pressure asheretofore described. Thus the clamping ram 22 and the seat'of theinjection nozzle are placed under the same unit pressure;

As a consequence of setting of valve 406 the oil pressure builds up inline 4H5 until it reaches a value higher than the initial pressurecontrolled by valve 406 equal to the setting of valve till and y thenpasses through sequence valve 455 through the line 4H, valve M8, line435 to the upper side of the cylinder IBI to advance the plunger I31 inthe cylinder I20. At the" same time the oil which passes beyond theva1ve'4i5 also passes through line 425 to exert a pressure on a controlfor the high pressure pump to lower the delivery of the pump and tomaintain the pressure as set by pressure adjustment on the pump. Thefluid under high pressure, passing through valve M5, passes through intothe upper end of H2, while the lower end of the bore I12 is on exhaustthrough the port E89, line 430 "through valve 431 into the valve 4 I 8and through line 440 connected to the tank ii. As the'oil feeds into theupper part of the chamber I12, the pressure built up thereby actsagainst the upper face of the piston head 02 to move the ram I80 and theinjection plunger I3! downwardly in a center line coincidental with thatof cylinder I3. In the course of itsinitial travel the ,free endof theinjection plunger moves from a positionas shown in-Fig.'5 and near theupper limit of the passageway l56 through the cylinder, 120, firstslightly cornpresses the granular fusible plastic material fed solely bygravity fromth'e hopper I55 to completely fill the free space thereinwith rather loosely compacted material.

The 'free end of the plunger I31 acts upon the granular material whose,angle of rest is approximately that of the angle at which the free lowerface of the plunger I3! is disposed to the horizontal so that a completefilling is automatically effected. The plunger I31, in the course offirst compacting the loose material, closes off the passageway I theperiod between stages D (Fig. 18) and M (Fig. 19) and continuesdownwardly to further compact the material and apply pressure to theportion thereof located in the lower part of the cylinder I20 and whichhas been softened 'or its viscosity substantially reduced. This pressureis transmitted thereto, whereby the material of lower viscosity at thelower end of cylinder I20 is forced through the openings in the nozzleIll and out of the nozzle through the sprue bushing 09 and against thesprue remover 60 whose teat 02 acts as a shallow spreader whereby thematerial maybe evenly fed and fill the space between the dies and con-'-tinues' to move downwardly until it reaches the stage 'E (Fig. 19') tothereby build up the injec-.

tion pressure on the injected material, so that a force of about 2000 to2500 pounds per square inch is exerted thereby on the movable die in adirection opposite to that force exerted-by the clamping ram 22. Theinitial clamping pressure in the period between'the stages C toG (Fig.20) is maintained substantially constant and the pressure in the periodbetween the stages E and F is also maintained substantially constantwith the pressure in the period between the stages E to F, being greaterthan the initial clamping pressure during that same period, so that thepressure per unit of area in the mold bosses in order that a slightspreading action between the die heads may occur.

The pressure of the plunger I3! is controlled by the control of the highpressure pump automatically reducing its volume when a pre-set pressureis reached in the injection cylinder. Due to the water circulation inthe die heads and because the newly formed record 8 sets quicker thanthe sprue, which is thicker in cross section and'therefore notcompletely set, the sprue remains softer than the record. The settingcycle, which is also indicated in Fig. 25, initially starts at about thestage E, the time the maximum injection pressure is reached, andcontinues in the period between the stages E andF. After a period oftime which is suited to various conditions involved, such periodbeingcontrolled by the electric timer Ta, timer Ta times out and resets,whereupon solenoid'443 is de-energized and solenoid 444 is energized.-The valve M8 is shifted so as to direct the oil under pressure throughline 436 over foot valve 43] through passageway I89 to the lower part ofchamber NZ to return the piston I82 upward and at the same time theupper'part of thechamber is on exhaust through the line 435 through thevalve 458 to tank 5. Simultaneously the oil under pressure is admittedthrough branch 438 to passageway 05, chamber 64 and acts upon the lowerface of the ram rod causing it to move upward as indicated in Figure 20between the stages F and G, whereby the sprue remover 00 punches a cleanhole 9 through record 8 and pushes the sprue up through bushing 99 andin the dis charge end of the nozzle III and mostly beyond its restrictedorifice I4I. It further serves to provide a seal to maintain thepressure within the die.

Then as the piston I82 reaches the end of its retraction stroke, itstrikes a limit switch 45I whereupon electric timer Tb is started andsolenoid 442 is energized controlling the valve 401, so that the oilunder high pressure through line 408 passes through valve 401 to by-passthe controlled mechanism of valve 406 to the passageway 404 to thecylinder I3 to build up a final clamping pressure of approximately 2750to 3000 pounds per square inch of the dies as indicated at stage G.Retraction of piston head I82 retracts the injection plunger I3'Iupwardly beyond the passageway I56 to move to its former position,whereupon a new charge of granular'material automatically dischargesthrough the passageway I56 on top of the heated charge in the lower partof the cylinder I to substantially completely fill the void between thespreader and the cylinder. It was found that in the cooling of therecord a slight contraction occurs, and it was because of this that aslight spreading action was allowed in the forming of the record; so atthis point increased clamping pressure can follow up the contraction toimpart to the record sharp impression from the matrices for theremainder of the curing period controlled by an electric timer Tb. Thisincreased clamping pressure reaches a maximum and is maintained for acontrolled period of time in the period shown between stages G and H.

The the timer Tb clocks out at stage H solenoids 440 and 444 arede-energized and solenoid 44I is energized, whereby the valve 402 isactuated, whereupon a branch of the line 404 connected to port isconnected to valve 402 through line 424 to the tank 5 and high pressurefluid through pipe 403 feeds through port 28 through the upper end ofthe bore I1 driving the ram 22 rearwardly until it reaches the positionshown in Fig. 24, and being in its maximum contracted position. As thefluid is admitted through the line 403 to the upper end of cylinder I3,the pressure built up thereby acts against 7 In the course of retractionof the ram 22 the high pressure fluid is admitted from line 403 throughport I9I to the upper'end of bore I98 to drive the injection unitupwardly only a slight distance, which movement is controlled by thestop cams 242 and 243 located in operative position. This slightmovement of the injection unit unseats the spherical end of the nozzle adistance of one thirty-second of an inch from the seat of the spruebushing 99 and remains in this condition until the stage B of the newcycle is reached.

When the ram 22 attains its maximum retracted position at stage I (Fig.21) the pressure builds up in the fluid in the upper part of bore l1 andis transmitted through the passageway 68 to the lower part of the bore40 and acts against the lower face of the piston head 31 to drive thecompound piston and record stripper 41 upwardly while the upper part ofthe bore 40 is on exhaust through the passageway 61, Simultaneously, theliquid under pressure which flows 16 into the lower part of the bore 40flows through grooves in the lower part of the compound piston to theupper part of the bore 6|, while the lower part of the bore BI is onexhaust through line 438 and valve 8, to return the ram rod 60 to itsmaximum retracted position. At the same time the stripper is beingdriven upwardly against the center ofthe record which is held to matrix16 by the short inwardly extending flange or the shoulder 9|. Theoutward movement of the stripper 41 strips the record (Fig. 22) off ofthe movable die head and then the record drops downwardly into thereceiving end of the chute guide. The record reaching the chute willroll down the chute gradually tilting until it leaves the chute in aflat position and there deposits on and is carried by the conveyor belt330. While traveling towards the chute the record strikes and actuates amicroswitch 332 which starts the next cycle at stage B. In its progresson the conveyor, the still warm record is weighted to maintain itsflatness characteristic.

While the invention has been described in detail, it is not to belimited to the exact construction shown, because it is susceptible tovarious changes and modifications within the scope thereof.

Iclaim:

1. An injection molding machine comprising fixed and movable chilleddies defining, when closed, a mold cavity, a sprue bushing openingthrough opposed surfaces of said fixed die, said bushing having alongitudinally continuous onediameter bore, one end of said bore openinginto said cavity, an injection cylinder having a nozzle end engaging theother end of said sprue bushing, an elongated rod having the diameter ofsaid bore and movably supported with respect to said movable dieco-axially of said bushing bore, said rod being movable from a retractedposition clear of said cavity to a position extending across saidcavity, through the entirety of said bushing and into said nozzle, meansto pressure inject heated thermoplastic material from said cylinderthrough said bushing bore into said cavity in the retracted position ofsaid rod to form a molded product having an integral sprue within saidbushing bore, and means to then move said rod from the retractedposition to said extended position to sever the sprue from said productand to return the sprue to the nozzle end of said injection cylinder.

2. An injection molding machine comprising cooled, fixed and movabledies defining, when closed, a mold cavity, a sprue bushing openingthrough opposed surfaces of said fixed die and having a common diameterbore extending the major portion of its length and opening into saidcavity, an injection cylinder having a nozzle fixed to one end thereof,said injection cylinder being reciprocably movable to retractably engagesaid nozzle with said sprue bushing, an elongated rod having a diametercommon with the diameter of said bushing bore, said rod being movablewith. respect to said movable die co-axially of said bushing bore from aretracted position, extending slightly into said cavity, to a positionextending across said cavity through the entirety of said bushing boreand into said nozzle when the dies are closed and said nozzle is engagedby said bushing, means operable upon engagement of said nozzle with saidbushing to inject heated thermoplastic material from said cylinderthrough said bushing bore and into said cavity to form a solidifiedmolded product having an

